Documente Academic
Documente Profesional
Documente Cultură
F. Hvidbak
flemingCo environmental aps
Sulsted, Aalborg, Denmark
consult@flemingco.dk
Abstract
The perspective of this paper is to provide responders and authorities with a
broader understanding of the most advanced pumping technologies and techniques
that are available for one of the most difficult tasks in mechanical response to spills
of heavy and extreme viscosity oil: Extreme viscosity pumping.
The so-called positive displacement Archimedes’ screw (PDAS) pumps have
within the oil spill industry for several years been considered superior to other
pumps as regards the transfer of debris laden and often very viscous and difficult-to-
deal-with oil or water-in-oil emulsions. Their ability to handle viscous oils, solids, to
cut debris, and to pump oil and water without causing the creation of emulsion has
together with relatively low weight and small dimensions - when compared to the
performance - cemented the position of these pumps in the market.
There are presently four PDAS pump brands on the oil spill response market,
which all have their origin in a patent, which was taken by Goodyear in 1955.
This presentation will describe their historical development and provide
insight to the technology: From the design of the original Goodyear pump, based on
a gear box principle, to the DESMI and GT cooperation on the first Destroil screw
pump. It will cover their split-up following GT’s design of its own version, and
DESMI’s reaction with the launch of the DOP pump type. It will go through
FOILEX’ special variant, and will complete the picture with the new Lamor GT-A.
The technical differences between the pumps, their capacities, pressure ratings,
availability of performance curves, and selection of materials will be discussed.
Increased awareness of the need to respond to spills of high and extreme
viscosity oil, has led to the development of new flow enhancing water injection
techniques, which enable the PDAS pumps to transfer even the most extreme
viscosity oils and emulsions at operational pumping rates over operational distances.
Summary results from full scale tests of the new techniques will include testing at
manufacturers and at the Canadian Coast Guard / Environment Canada in Ottawa,
February 2002. All four pump brands and all the existing and new flow enhancing
techniques will be tested in the coming Joint US and Canadian Coast Guard Viscous
Oil Pumping System testing that will take place in the US late 2003.
1 Introduction
The so-called Positive Displacement Archimedes’ Screw (PDAS) pumps
have within the oil spill industry for several years been considered superior to other
pumps as regards the transfer of debris laden and often very viscous and difficult-to-
deal-with oil or water-in-oil emulsions. The pumps are able to handle viscous oils,
solids, to cut debris, and to pump oil and water without causing the creation of
emulsion. This has together with low weight and relatively small dimensions - when
compared to their performance - cemented the position of these pumps in the
market.
Despite the good performance on heavy oil the PDAS pumps will be
severely challenged on extreme viscosity oil like for instance bitumen or very cold
heavy oil. The oil will not freely flow into the pump and even if it does get into the
pump the friction inside the pump and in the discharge line may be more than the
pump can handle without causing damage to itself, its hydraulic motor, or the
discharge hose. It is therefore in such situations necessary to use a flow enhancing
technique in order to pump the product over an operational distance at an operational
rate.
Figure 2 Destroil DS-210 Pump (left) and Blomberg (right) w. 1st Prototype
Figure 3 GT-185 Pump Cutaway with Inlet Hopper for Weir Skimmer
Almost at the same time as the DOP-250 was launched to the market, a GT-
260 pump with the same capacity as the DOP-250 was introduced. However, it was
still of the old horizontal design with both feeding- and pump screw section, and its
weight was 275 kg, more than three times that of the similar capacity DOP pump.
Figure 5 Foilex TDS Off-loading Pump and its Pumping Geometry (right)
Figure 7 The Lamor GT-A Pump Series with a Cutaway Pump to the right
DESMI
DOP/DS-250* 75 / 165 10 / 147 100 / 440 @ 800 125@1000 w. lower torque motor
DOP-250 Dual* 80 / 176 10 / 147 100 / 440 @ 800 125@1000 w. lower torque motor
DOP-160 31 / 68 10 / 147 30 / 132 @ 1000
FOILEX
TDS 250* 120/265 10 / 147 165 / 726 @ 750
TDS 200* 90 / 198 10 / 147 85 / 374 @ 780
TDS 150* 35 / 77 10 / 147 45 / 198 @ 900
GT
GT-185* 81 / 178 7 / 103 45 / 198 @ 600
GT-260* 275/604 7 / 103 100 / 440 @ 500
LAMOR
GT-A 115* 72 / 158 12 / 176 114 / 502 @ 800 140@980 w. lower torque motor
GT-A 50 47 / 103 12 / 176 62 / 272 @ 980
GT-A 20 25 / 55 12 / 176 20 / 88 @ 1000 30@1500 w. lower torque motor
* Note: These pumps will require higher torque / lower RPM motor on very high or
extreme viscosity oil
3.1 Pump performance curves
Performance curves, especially if they have been certified by a bureau of
classification, can provide the potential pump customer as well as a pump owner
with valuable information on a given pump. Normally the curves will be based on
water testing, especially when each produced pump is tested to verify that it meets
the requirements set forth in the manufacturers quality control system (few
customers will purchase a pump, which has already been in black and sticky oil). A
test curve on water cannot tell directly about heavy oil capabilities, but it can
disclose tolerance errors in the various sealing mechanisms and can verify the
pump’s water pumping capability. The performance curve for a specific pump
production number can also prove to the customer that the pump has been operated
minimum for the duration of the test, which for the manufacturer would be enough
to detect and correct any malfunctions.
DESMI
• Performance curves on water, flow vs. pressure, are available for DOP-160,
DOP-250, and DS-250.
• Performance curves on oil of various viscosities up to 60,000 cSt, flow vs.
pressure, are available for DOP-250 and DS-250
FOILEX
• No performance curves are readily available, but they can be provided upon
request for all Foilex pumps. The curves are on 1000 cSt oil.
GT
• No performance curves are available
LAMOR
Performance curve on water, flow vs. pressure, is presently available for the GT-
A 50 (Will be available later in 2003 for the GT-A 20 and GT-A 115 according
to the manufacturer).
3.2 Materials, seals, and wear protection
Table 2 displays the materials that the manufacturers have selected for their
pumps and discloses design details related to sealing against back-flow and to wear
protection.
LAMOR Marine gr. Acid proof Acid Replaceable Replaceable SST inserts
aluminium st. proof st. PE-HD or PE-HD or in plate
PTFE sealing PTFE discs on wheel casing
acid proof sides and
steel core rounding
Note: Bold text is standard version
• No or limited emulsification of water and oil. Most other pump types will
create the very viscous and difficult-to-deal-with water-in-oil emulsion if oil
and water are pumped simultaneously. But the PDAS pumps will in principle
for each revolution cut a segment of “thread” out of the pumped product and
push it through the pump in a very gentle manner. It might be better
explained by thinking about pumping children’s toothpaste with stripes:
There would still be stripes after the pump; but no mixing or emulsification.
• Good debris handling. All four pumps have cutting knife systems, which
chop up lots of the debris that could seize the operation for many other pump
types. Furthermore the open structure plays an important role when the
chopped debris must be brought forward through the pump.
• Good solids handling is due to the very open structure of these pumps. It
should, however, be noted that solids (stones, pieces of steel, etc.), which
happen to be hit by the knives may not pass through the pumps unless the
knives can chop them up. It is quite random whether a solid, that would
otherwise pass through the pump, will be hit by the knives and - if strong
enough - thereby cause the pump to stop instantaneously. It could therefore
seem that fewer knives would result in a higher chance that the solid passes
through
• Good performance on heavy oil or high viscosity oil is really what the pumps
are famous for. Once again the open structure plays an important role, as
does the gentle treatment of the oil. A relatively small portion of the pump
power is used for sliding, squeezing, and attempting to compress the oil,
which is very power demanding with higher viscosity oil. This leaves more
for the task to move the product forward. Or in other terms: The pumps have
an overall high efficiency on high viscosity oil.
• Mobility: All the PDAS pumps are made for mobile use, and especially the
smaller pumps offer the important combination of portability and heavy oil
performance.
• Wear may be a problem due to the fundamental design of the PDAS pumps
where the moving parts slide against each other and the pump casing. This is
especially the case when pumping abrasive media. The problem has caused
two of the manufacturers to place relatively inexpensive wear (and sealing)
parts at critical locations to protect mainly the pump casing (Table 2).
1. It heats up the inner surfaces – including the moving parts – so that the oil
touching the surfaces – locally, in a very thin layer – gets heated up. This
reduces the viscosity of the thin oil layer, thus significantly reducing friction
inside the pump.
2. Friction is further reduced by the lubricating effect of the injected hot water,
which in turn also lubricates the discharge line and facilitates the overall
transfer of the oil.
Figure 9 flemingCo Inlet Side Steam Injection System and Bitumen Test
It was at this test observed that the DOP-250 pump had to be equipped with
a higher torque / lower RPM hydraulic motor in order to efficiently deal with the
extremely viscous product. It was further observed that heating the bulk of the
bitumen from 15 to 30 °C, thus reducing the viscosity from above 3 million cSt to
about 200,000 cSt, was sufficient for an operational pumping capacity without the
aid from other flow enhancing technique than the bulk heating.
It should be noted that the GT-185 by purpose had been equipped with steam
injection devices on both inlet- and discharge side, since it was the expectation that
the many inner leaks in the pump would cause a backflow of the steam/water
injected at the inlet, which would result in too little water left for further lubrication
through the remaining part of the pump and the discharge hose.
It was at this test observed that the GT-185 pump had to be equipped with a
higher torque / lower RPM hydraulic motor in order to efficiently deal with the
extremely viscous product.
7 Coming Testing
The coming Joint US and Canadian Coast Guard and Industry Viscous Oil
Pumping System (JVOPS) testing that will take place in the US late 2003 has been
planned for more than a year and it was originally expected that this presentation
could present the major test results. However, logistic problems, such as getting the
right oils for testing and controlling the viscosities, have delayed the project, which
is now scheduled for November 2003. The JVOPS project will be the most
comprehensive high- and extreme viscosity testing that has ever been carried out.
In one test line a product with a target viscosity of 200,000 cSt will be
pumped over a test distance of 300 ft using all the PDAS pump types in the market
plus two other pump types. All thinkable combinations of inlet side water
lubrication (hot, tempered, cold), discharge side water lubrication (hot, tempered,
cold), and local bulk heating will be applied. Several different percentages of
injected water will be used in an attempt to determine the optimal injection rate
relative to the pumped product. In order to verify whether proportionality exists
when using the best flow enhancing technique or if additional water must be added,
the pumping distances will for one of the test pumps gradually be increased up to a
maximum of 450 m (1500 ft ) of 6” hose.
In another test line the same pumps and test pattern will be used on a product
with a target viscosity in the 500,000 to 1 million cSt range, except for that only
inlet- and outlet hot water injection and combinations with local bulk heating will be
used. These extreme viscosity tests will likewise conclude in a test with gradually
increasing pumping distances, namely from 30 to 150 m (100 to 500 ft) of 6” hose.
9 Conclusion
There are with the combination of positive displacement Archimedes’ screw
pumps and the various flow enhancing techniques clearly means available for the
difficult task of extreme viscosity pump transfer. It will be up to the individual
response organization to decide on which pump type and flow enhancing technique
will suit their needs and existing equipment inventory in the best possible way.
Several combinations will obviously work.
It must, however, be noted that some of the PDAS pumps will need to be
equipped with a higher torque / lower RPM hydraulic motor than what is standard
for these pumps.
When the coming JVOPS testing in the US has been completed it is expected
to be possible to clearly quantify, for each pump type, the optimal application of
heat and water injection when pumping high and extreme viscosity oil.
10 Biography
Flemming Hvidbak is an oil spill consultant who has been in the industry for
19 years. He has specialized in developing and testing response techniques and
equipment for spills of heavy and extreme viscosity oil. Presently he serves as lead
engineer for the coming joint US Coast Guard, Canadian Coast Guard, and Industry
viscous oil pumping system tests in the United States, 2003.
11 References
Cooper, D., SAIC Canada, Hvidbak, F., flemingCo, 2000. “Evaluation of
Mechanical Recovery Devices for Spills of Orimulsion®”, SAIC Canada Technical
Report, 2000.
Cooper, D., SAIC Canada, Hvidbak, F., flemingCo, Mitchell, T., Breco Innovation,
2000, “Pumping Extremely Viscous Oil Using a Modified GT-185”, SAIC Canada
Technical Report, 2002.
Hines, D., Environment Recovery Equipment, Inc., 2002, “Heavy Viscous Oil
Pumping Tests / Demonstrations at ERE Facility in Port Colborne, Ontario, Canada”
http://www.ereweb.com/heavy_viscous_oil_pumping.htm, 2002
Hvidbak, F., flemingCo, 1999. “Projects for the Detection and Recovery of Spilled
Orimulsion®, Evaluation of the UNISEP and KLK Skimmers”, Bitor America
Corporation Technical Report, 1999.
Hvidbak, F., flemingCo, 2002. “Test and Evaluation of the LAMOR Brush Belt
Skimmer on 3+ million cSt Bitumen”, Bitor America Corporation Technical Report,
2002
Moffatt, C., GPC, US Coast Guard and US Navy, 1999. “Testing of the U. S. Coast
Guard Viscous Oil Pumping System (VOPS Prototype) at the MMS OHMSETT
Test Facility, Earle, NJ, November 1999”. USCG /US Navy / GPC technical report
1999.